Section 14, Aileron Frames, Right and Left, SeaRey, LSA

Progressive Aerodyne, Inc.

3801 State Rd 19
Tavares, FL 32778

Document Number
Revision Description Remarks Date
01 Initial Creation TBD 10/26/2009
02 Update 01262012 01/26/2012

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 Section 14, Aileron Frames, Right and Left, SeaRey, LSA
1.0 Scope
This document will detail the steps necessary to assemble a SeaRey LSX Aileron frame assembly up to, but not including covering.

2.0 Applicable Documents

N/A

3.0 Requirements

3.1 Equipment
3.1.1 The following tools will be necessary to perform this procedure:
 Socket, 3/8”
 Socket 7/16”
 Wrench, Open End, 3/8”
 Wrench, Open End, 7/16”
 Rivet Gun
 Awl
 Center Punch
 Drill Bit, 3/32”
 Drill Bit, 3/16” (Long)
 Allen Wrench, 3/16”
 Cleco Pliers
 Clecos, 1/8”

3.2 Materials
The following general supplies will be necessary to perform this procedure:

 N/A

3.3 Procedure (see the following pages)

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 Section 14, Aileron Frames, Right and Left, SeaRey, LSA

Aileron Leading
Edge Inboard

Outboard Nutplate 1/4-28 Inboard

Nutplate 1/4-28

Figure 1. Attaching Nutplate to Aileron Leading Edge LS

Note: in the following step the Nutplate should be on the same side of the tube as the drilled 1/2” holes.
Note: The inboard end has a 1/4” hole close to a 1/2” hole.

1.1 Insert Bolt AN4-20A (#N420A) into each of the three (3) 1/4” holes in Aileron Leading Edge (#5760-009), then thread Nutplate
1/4-28 (#NP1/4-28) lightly onto each Bolt AN4-20A.
1.2 Align Nutplate(s) 1/4-28 (#NP1/4-28) along the leading edge tube as shown in Figure 1.
1.3 Using a 3/32” drill bit, drill through ONE side of the mounting lug hole of the Nutplate (#NP1/4-28).
1.4 In the hole just drilled, rivet using Rivet CCR-264-SS-3-5 (#264CR35).
1.5 Drill the remaining mounting lug in Nutplate (#NP1/4-28) using the 3/32” drill bit.
1.6 Rivet Nutplate to tube using Pop Rivet CCR-264-SS-3-5 (# 264CR35).
1.7 Repeat Steps 1.3 – 1.6 for remaining Nutplates.
1.8 With Nutplates riveted firmly in place against Aileron Leading Edge (#5760-009), remove Bolt AN4-20A.

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 Section 14, Aileron Frames, Right and Left, SeaRey, LSA

1/2” Hole
Rivet
1/2” Hole AB6-8A

Rib Insert Rib Insert 1/2” Hole Rib Insert

Aileron Leading Edge

Rib Insert

Figure 2. Attaching Rib Inserts to Aileron Leading Edge

2.1 Locate the (6) 1/2” holes with the 3/16” holes drilled inline through the leading edge of the Aileron Leading Edge (#5760-009).
Place Rivet, AB6-8A (#P-68) into the 3/16” hole.
2.2 With a pair of needle nose pliers grasp a Rib Insert (#5520-007) and drop it onto the rivet head through the 1/2” hole.
2.3 Rivet each of the (6) Rib Inserts into the Aileron Leading Edge (#5760-009) at the 3/16” holes. Refer to Figure 2.

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 Section 14, Aileron Frames, Right and Left, SeaRey, LSA

Rib Insert Rivet AB6-8A Rib Insert

Aileron Trailing Edge

Rib Insert

Figure 3. Attaching Rib Inserts to Aileron Trailing Edge

3.1 Locate the (6) 3/16” drilled holes in the Aileron Trailing Edge (#5760-008). Place Rivet, AB6-8A (#P-68) through Rib Insert (#5520-
007) and rivet each of the (6) Rib Inserts onto the Aileron Trailing Edge (#5760-008) at the 3/16” holes. Refer to Figure 3.

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 Section 14, Aileron Frames, Right and Left, SeaRey, LSA

Aileron Compression Strut(s)

Inboard
Aileron
Leading Edge
6 5 4 3 2 1

Aileron
Outboard Leading Edge
Rib Insert Aileron Compression Strut

Figure 4. Attaching the Aileron Compression Struts to the Aileron Leading Edge

Note: The inboard end has a 1/4” hole close to a 1/2” hole.

4.1 Insert (the longest) Aileron Compression Strut #1 LS (#5760-004/01) starting at the Inboard end of the Aileron Leading Edge
(#5760-009). Tap the Aileron Compression Strut #1 into the 1/2” hole. Drive it in far enough until it seats over the Rib Insert
(#5520-007) and touches the surface of the Aileron Leading Edge (#5760-009). See figure 4 above.
4.2 Continue installing the Aileron Compression Struts #2 through #6 (#5760-004/02 - 06) in the same manner as step 4.1.

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 Section 14, Aileron Frames, Right and Left, SeaRey, LSA

Aileron Aileron Compression

Trailing Edge Strut(s) Aileron Trailing
Edge Inboard

Rib Insert 6 5 4 3 2 1

Outboard Aileron
Aileron Compression Strut Leading Edge

Figure 5. Attaching the Aileron Trailing Edge onto the Aileron Compression Struts

Note: The Aileron Trailing Edge will only match up to the Aileron Compression Struts one way.

5.1 Align the Rib Inserts on the Aileron Trailing Edge (#5760-008) with the ends of the Aileron Compression Struts (#5760-004/01-06).
Starting at the inboard end, place Aileron Compression Strut #1 (#5760-004/01) over the Rib Insert (#5520-007). Push it in far
enough until it seats over the Rib Insert (#5520-007) and touches the surface of the Aileron Trailing Edge (#5760-008). See Figure
5 above.
5.2 Continue installing the Aileron Compression Struts #2 through #6 (#5760-004/02 – 06) in the same manner as step 5.1.
5.3 When the assembly is complete, place some tape around the #2 and #5 Aileron Compression Struts (#5760-001) and wrap
around the Aileron Trailing Edge (#5760-008) to hold together until the fabric installation occurs later.

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 Section 14, Aileron Frames, Right and Left, SeaRey, LSA

Aileron Aileron Compression Strut

Trailing Edge

Aileron Compression Strut

End Cap, 11”

Pop Rivet Outboard
End Inboard End
End Cap, 6”

Figure 6. Installing the Aileron End Caps Inboard and Outboard

6.1 Place the End Cap, 6” (#5750-022) against the Aileron Compression Strut #6 (#5760-004/06) on the outboard end. Using a
clamp, hold the End Cap, 6” in position against the Aileron Compression Strut.
6.2 Go in approximately 1” from each end of the End Cap, 6” (#5750-022) and place a mark in the center that will line up with the Aileron
Compression Strut #6 (#5760-004/06).
6.3 At the two marks drill a 3/16” hole through the End Cap, 6” (#5750-022) and into one side of the Aileron Compression Strut.
6.4 Using a Rivet, AB6-6A (#P-66), rivet the End Cap, 6” (#5750-022) to the Aileron Compression Strut #6 (#5760-004/06).
6.5 Repeat Steps 6.1 to 6.4 to install the End Cap, 11” (#5750-013) to the inboard end on Aileron Compression Strut #1 (5760-
004/01).

Note: Aileron Gap Seal Inboard and Outboard (#5760-005, 5760-006) and Aileron Control Horn assembly will be installed after fabric
covering and painting.

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